CRUV. Electric Humidifier. Installation, Operation, and Maintenance Manual

Transcription

1 CRUV Electric Humidifier Installation, Operation, and Maintenance Manual

2 ATTENTION INSTALLER Read this manual before installing. Leave manual with product owner. DRI-STEEM technical support WARNING! Disconnect electrical power before installing supply wiring. Contact with energized circuits can cause severe personal injury or death as a result of electrical shock. This product must be installed by qualified HVAC and electrical contractors and in compliance with local, state, federal, and governing codes. Improper installation can cause property damage, severe personal injury, or death as a result of electric shock, burns, and/or fire. The humidifier tank, dispersion assembly, and all connected hose or piping can contain or discharge hot steam and/or hot water at 212 F (100 C). Discharged steam is not visible. Contact with hot surfaces, discharged hot water, or air into which steam has been discharged can cause severe personal injury. Failure to follow the instructions in this manual can cause moisture to accumulate, which can cause bacteria and mold growth or dripping water into building spaces. Dripping water can cause property damage; bacteria and mold growth can cause illness. Supply water pressure greater than 80 psi (550 kpa) can cause the humidifier to overflow.

3 Overview Product overview...4 Specifications, capacities, and weights... 6 Dimensions...7 Installation Choosing a location...8 Mounting the humidifier...9 Piping...10 Supply water and drain piping...13 Wiring...14 Humidistat and transmitter placement...15 Dispersion Interconnecting piping requirements Drip tee installation...19 Single tube...20 Rapid-sorb...22 Operation Start-up and operation: Standard water models...30 DI water models...33 Maintenance Water quality...34 Standard water models...35 DI water models...38 Troubleshooting guide...42 Replacement parts Humidifier...46 Control cabinet with Vapor-logic3, SSR Control cabinet with Vapor-logic Note: The Vapor-logic 3 Installation and Operation Manual is a comprehensive operation manual. Refer to it for information regarding the following features: information The Vapor-logic3 manual was shipped with your humidifier. Additional copies can be viewed, printed, or ordered at Download DRI-STEEM literature Most DRI-STEEM product manuals can be downloaded, printed, and ordered from our web site: Warranty...back cover

4 Overview Notes: Damage caused by chloride corrosion is not covered by your DRI-STEEM warranty. CRUV standard water models control water levels with an electronic probe CRUV standard water models (shown below) require supply water conductivity to be least 100 μs/cm to operate. These models use an electronic probe to monitor water levels (see Figure 5-4). Standard water models will not operate with water treated by reverse osmosis (RO) or deionization (DI) processes. CRUV-DI models control water levels with a float valve CRUV-DI models are designed specifically for use with DI/RO water. These models use a float valve to control water levels (see Figure 5-5). CRUV-DI models will not operate with standard (potable) water. Convert to a different water type in the field CRUV standard water models can be converted in the field for use with DI/RO water. CRUV-DI models can be converted in the field for use with potable or softened water. Contact your DRI-STEEM representative or distributor for parts and instructions. Figure 4-1: CRUV humidifier Standard water model DI water model Steam outlet Probe Heater terminal cover Steam outlet Float switch Heater terminal cover Strainer Fill valve Over flow Cover Cover bolts Water supply Over flow Cover Cover bolts Heater element Heater element Electric drain Tank temperature sensor OM ½" SST ball valve Tank temperature sensor OM-770-2

5 Overview Figure 5-1: Ultra-sorb dispersion Figure 5-4: Water level control for standard water systems Fill valve closes OM-7475 Fill valve opens Low-water cutoff Figure 5-2: Rapid-sorb dispersion Systems using tap or softened water control water levels electronically using a three-rod probe. The controller responds with the above actions when the water level reaches each rod. VLC-OM-030 Figure 5-5: Water level control for DI/RO water systems Supply water connection OM-2007 Float rod Float ball Figure 5-3: Single or multiple tube dispersion Systems using deionized (DI) water or water that has been treated through reverse osmosis (RO) control water levels using a float valve and low water cutoff switch. OM-7396 OM-2006

6 Overview Table 6-1: CRUV specifications CRUV CRUV-DI model (kw) Maximum steam capacity** Single-phase Current draw (amps) Three-phase Shipping weight*** Operating weight*** lbs/hr kg/h 120V 208V 240V 480V 600V 208V 240V 480V 600V lbs kg lbs kg * 14.4* 7.2* 5.8* * 21.7* 10.8* 8.7* * 28.9* 14.4* 11.5* * 25.3* 12.6* 10.1* Notes: * For wire sizing, the highest leg draw is shown due to current imbalance. ** Total humidifier load = load to meet design conditions + load to compensate for steam loss from the dispersion assembly and interconnecting piping. If total humidifier load is more than the humidifier's maximum capacity, design conditions will not be met. For steam loss data see the DRI-STEEM Design Guide available for downloading and printing at *** Depending on configuration, add up to 28 lbs (13 kg) for weight of control cabinet, subpanel, and other electrical control components.

7 Overview Figure 7-1: CRUV dimensions Top view B Front view A C F C Side view D E OM-2004, OM-2002, OM-2003 Table 7-1: CRUV dimensions CRUV/CRUV-DI model number A B C D E F inches mm inches mm inches mm inches mm inches mm inches mm 2, , , 12, 14, , 25, 30,

8 Installation Figure 8-1: Installation in an air conditioning unit Locate the CRUV humidifier near an electric power source, water supply and a drain. Verify that sufficient room is provided for a water seal in the drain piping (see Figure 10-1). In an air conditioning unit When installing a humidifier inside an air conditioning unit, provide adequate support; allow easy access for removing and servicing the evaporating chamber, and provide adequate clearance to install the vapor hose and dispersion tube (see Figure 4-1) and water seal. See Figure 7-1 for mounting hole locations. In a duct When installing the dispersion tube in a duct, allow for a continuous pitch of the vapor hose back to the evaporating chamber. Otherwise, use a water seal and drain (see Figures 8-2 and 9-1). The dispersion tube can also be placed vertically in the duct with some models (see Figure 9-3). Place the control cabinet or electrical sub-panel in a grounded protective metal enclosure and mount in a dry and accessible location. OM-2008 If draining the evaporating chamber by gravity is not possible, use a small condensate lift pump, rated to pump 212 F/100 C water. Figure 8-2: Horizontal dispersion tube Duct Vapor Hose Horizontal mounting of dispersion tube in a duct, connected via vapor hose to a wall-mounted CRUV humidifier. OM-2006

9 Installation When horizontally mounting the dispersion tube in an air stream that is located lower than the CRUV humidifier a water seal (to prevent steam from escaping at the open drain) must be provided in the drain line and line extended to open drain, as shown in Figure 9-1, to drain the condensate. The dispersion tube can be mounted vertically in the duct. Note: When dispersion tube is more than 10' (3 m) from unit, insulated, 1½" (38 mm) diameter minimum rigid tubing or pipe should be used instead of vapor hose. This application is not recommended for CRUV-10 through CRUV-34. When rapid absorption is extremely critical, a Rapid-sorb can provide 100% steam absorption within three feet or less - at any duct temperature. A multiple tube or Rapid-sorb is required for CRUV-30 or CRUV-34 because of their high output. See Figure 9-2 and the Rapid-sorb section beginning on Page 22. Figure 9-2: Rapid-sorb dispersion Duct OM Figure 9-1: Horizontal dispersion tube lower than humidifier Figure 9-3: Vertical dispersion tube Duct 6" (152 mm) Duct Tee 8" (200 mm) Water Seal OM-7553 OM-775-1

10 Installation For complete information on calculating the number of dispersion tubes required to satisfy steam absorption distance requirements, consult your local DRI-STEEM representative, the DRI-STEEM factory, or use DRI-STEEM's Dri-calc selection software. Water make-up piping should be of corrosion-resistant, codeapproved material (copper, steel, or plastic). The final connection size is ¼" pipe thread. In cases where water hammer is possible, a shock arrestor should be considered. Drain piping should be of code approved material (copper, steel, or plastic rated for 212 F/100 C minimum). See Figure The ¾" O.D. copper sweat connection should not be reduced in size. If there is no sewer available for drainage, the unit can be piped for manual drainage. Consult factory for instructions. Figure 10-1: Water seal piping Water seal must not be above bottom of frame Note: provide 1" (25 mm) air gap to eliminate back siphonage 12" (305 mm) Floor drain Sanitary sewer OM

11 Installation Figure 11-1: Field piping overview for CRUV models (standard water models) Water supply inlet If water piping to humidifier is nonmetallic, we recommend a 2" (50 mm) metallic water seal or loop in the supply line to isolate steam during maintenance Water supply line; water pressure range 25 psi to 80 psi (172 kpa to 552 kpa); first 3' (1 m) of supply line must be rated for 212 ºF (100 ºC); water conductivity minimum (100 μs/cm) Shock arrester recommended to reduce water hammer Water inlet strainer Steam vapor hose Install plumb Electrical conduit knockouts: combination knockout for ½" and ¾" conduit connectors (knockout dias mm and 28.6 mm) combination knockout for ¾" and 1" conduit connectors (knockout dias mm and 34.9 mm) Tank surfaces will reach 212 F (100 C) when operating. Provide outer protection from direct contact, but allow for natural ventilation. If run is over 10' (3 m), increase pipe to 1¼" (DN32) Pitch 1/8"/ft (1%) Tank support by installer 6" (152 mm) recommended 12" (305 mm) minimum Drain Skim/overflow port ¾" (DN20) union for skim, drain, and overflow connection; plumbing rated for 212 F (100 C) 1" (25 mm) air gap Open drain required. See first note below. DC-1133 Figure 11-1 notes: Refer to governing codes for drain pipe size and maximum discharge water temperature. additional backflow prevention is required; however, governing codes prevail.

12 Installation Figure 12-1: Field piping overview for CRUV-DI models (DI water models) If water piping to humidifier is nonmetallic, we recommend a 2" (50 mm) stainless steel water seal or loop in the supply line to isolate steam during maintenance Water inlet strainer, by installer Water supply line; water pressure range 25 psi to 80 psi (172 kpa to 552 kpa); first 3' (1 m) of supply line must be rated for 212 ºF (100 ºC) Water supply inlet Skim/overflow port Steam vapor hose Electrical conduit knockouts: combination knockout for ½" and ¾" conduit connectors (knockout dias mm and 28.6 mm) combination knockout for ¾" and 1" conduit connectors (knockout dias mm and 34.9 mm) Install plumb Tank surfaces will reach 212 F (100 C) when operating. Provide outer protection from direct contact, but allow for natural ventilation. If run is over 10' (3 m), increase pipe to 1¼" (DN32) Pitch 1/8"/ft (1%) Tank support by installer 6" (152 mm) recommended ¾" (DN20) union for skim, drain, and overflow connection; plumbing rated for 212 F (100 C) 12" (305 mm) minimum 1" (25 mm) air gap DC-1135 Open drain required. See first note below. Figure 12-1 notes: Refer to governing codes for drain pipe size and maximum discharge water temperature. additional backflow prevention is required; however, governing codes prevail.

13 Installation Supply water and drain piping Supply water piping may be of any code-approved material (copper, steel, or plastic). The fill valve connection size is a ¼" pipe thread (DN8) fitting except in Europe where it is a DN10 pipe thread fitting. In cases where water hammer may be a possibility, consider installing a shock arrestor. Water pressure must be between 25 psi and 80 psi (175 kpa and 550 kpa). If water piping to humidifier is nonmetallic, we recommend that the first 3' (1 m) of water supply piping from the humidifier be metallic with a 2" (50 mm) water seal or loop in the supply line to isolate steam from nonmetallic supply piping. Drain piping may be of any code-approved material (copper, steel, or plastic rated for 212 F [100 C] minimum). If drainage by gravity is not possible, use a reservoir pump rated for 212 F (100 C) water (DRI-STEEM Part No for 120V pump and Part No for 230V pump). The final connection size is ¾" (DN20) copper for the tank and frame drains. Do not reduce this connection size. Pipe the tank and frame drains separately to prevent backflow of drain water into the humidifier cabinet. WARNING! Opening the drain valve when the tank is hot can discharge water with a temperature up to 212 F (60 C) into the plumbing system. This can cause damage to the plumbing system if the humidifier is not properly connected to a water tempering device such as a DRI-STEEM Drane-kooler. Do not touch the tank or drain piping until the unit has had sufficient time to cool, or serious injury can occur. Figure 13-1: Drane-kooler water tempering device If the equivalent length of pipe from the humidifier drain to the plumbing system drain is more than 10' (3 m), increase the pipe size to 1¼" (DN32). OM-7547 DRI-STEEM's Drane-kooler, shown mounted to a CRUV humidifier, tempers discharged water. For other Drane-kooler mounting options or for more information, contact your DRI-STEEM representative/distributor, or view the Drane-kooler product data sheet in the literature section at

14 Installation WARNING! Only qualified electrical personnel should perform field wiring installation procedures. Improper wiring or contact with energized circuits can cause property damage, severe personal injury, or death as a result of electric shock and/or fire. WARNING! DRI-STEEM strongly recommends installing a duct airflow proving switch and a duct high limit humidistat. These devices prevent a humidifier from making steam when there is low airflow in the duct or when the RH level in the duct is too high. Failure to install these devices can result in excessive moisture in the duct, which can cause bacteria and mold growth or dripping through the duct. Figure 14-1: Field wiring requirements Control cabinet Fused disconnect (provided by installer) OM-7552 Power supply (provided by installer) Notes: dedicated or separate earthed metal conduit, cable trays, or trunking. control circuit wiring when routing electrical wiring inside the humidifier cabinet. carrying commons. Never use a safety ground as a conductor or neutral to return circuit current. Humidifier field wiring All wiring must be in accordance with all governing codes, and with the humidifier wiring diagrams. The diagrams are located inside the removable subpanel cover on the right side of the humidifier cabinet. Power supply wiring must be rated for 220 F (105 C). When selecting a location for installing the CRUV, avoid areas close to sources of electromagnetic emissions such as power distribution transformers. The use of semiconductor fusing sized per the National Electric Code is recommended with the SSR option. Grounding requirements The approved earth ground must be made with solid metal-to-metal connections and must be a good conductor of radio frequency interference (RFI) to earth (multistranded conductors). Ground wire should be the same AWG (mm 2 ) size as the power wiring or sized per NEC requirements (in Europe, IEC requirements). Proper wiring prevents electrical noise. Electrical noise can produce undesirable effects on electronic control circuits, which affects controllability. Electrical noise is generated by electrical equipment such as inductive loads, electric motors, solenoid coils, welding machinery, or fluorescent light circuits. The electrical noise or interference generated from these sources (and the effect on controllers) is difficult to define, but the most common symptoms are erratic control or intermittent operational problems. Important: wire all humidity, high limit, and airflow controls using multicolored shielded/screened plenum-rated cable with a drain wire for the shield/screen. Connect the drain wire to the shield/ screen ground terminal with wire less than 2" (50 mm) in length. WARNING! Do not remove the humidifier electrical panel cover or the heater terminal cover until electrical power is disconnected. Contact with energized circuits can cause property damage, severe personal injury, or death as a result of electrical shock.

15 Installation Humidistat and transmitter locations are critical Humidistat and humidity transmitter locations have a significant impact on humidifier performance. DRI-STEEM recommends that you do not interchange duct and room humidity devices. Room humidity devices are calibrated with zero or little airflow; whereas duct humidity devices require air passing across them. See the following recommendations and the locations in Figure A Ideal humidistat or humidity transmitter location. Placement here ensures the best uniform mix of dry and moist air with stable temperature control. B Acceptable, but the room environment can affect controllability such as when the humidistat or transmitter is too close to air grilles, registers, or heat radiation from room lighting. C Acceptable, because this location provides a uniform mixture of dry and moist air. If there is a time lag between humidity generation and sensing, extend the sampling time. D Acceptable behind a wall or partition for sampling the entire room, if the sensor is near an air exhaust return outlet. Typical humidistat or transmitter placement for sampling a critical area. E Not acceptable, because these locations may not represent actual overall conditions in the space. F Not acceptable. Do not place humidistats or transmitters near windows, door passageways, or areas of stagnant airflow. G Best sensing location for a high limit humidistat or humidity transmitter and airflow proving switch. Figure 15-1: Recommended humidistat and transmitter locations Outside air Damper control Relief air Return air C Air handling unit 8' to 12' (2.4 m to 3.7 m) minimum G High limit humidistat or high limit transmitter (set at 90% RH maximum) for VAV applications Airflow switch or differential pressure switch (sail type recommended for VAV applications) Window Wall or partition Vapor absorption has taken place Point of vapor absorption A E D B F Humidifier dispersion assembly Turning vanes F E F Doorway Window DC-1084M mc_060508_0750

16 Installation Four places to find more information about dispersion 1. In this document: installation, Pages Pages installation instructions, Pages On our web site: The following documents can be viewed, printed, or ordered from our web site, wetting distance graphs): CRUV Ultra-sorb Maintenance manuals: Ultra-sorb Vapor-logic3 (includes information about sensors, and troubleshooting information) DRI-STEEM Design Guide (includes steam loss tables and general humidification information) 3. On Dri-calc: Dri-calc is our humidification system sizing and selection software, and can be ordered at our web site, com. Included in Dri-calc: guide documents, including: Rapid-sorb installation instructions for vertical airflows Recommended dispersion placement within a duct or air handler Recommended sensor placement Selecting the dispersion assembly location assemblies: single tube, multiple tube, Rapid-sorb, and Ultra-sorb assemblies, installed in ducts or air handling units required for absorption to occur. If you have questions about absorption distances, see the non-wetting tables in the CRUV catalog, available for viewing, printing or ordering at the water vapor being discharged is carried off with the airstream and is absorbed before it can cause condensation or dripping in the duct. air can most readily absorb the moisture being added without causing condensation at or after the unit. This normally will be after the heating coil or where the air temperature is highest. before the intake of a high efficiency filter. The filter can remove the visible moisture and become waterlogged. before coming in contact with any metal surface. before fire or smoke detection devices. before a split in the duct. Otherwise, the dispersion assembly can direct more moisture into one duct than the other. a 1" (25 mm) gap between the condensate drain piping and the drain. Locate air gap only in spaces with adequate temperature and air movement to absorb flash steam; otherwise, condensation may form on nearby surfaces. 4. Or call us at While obtaining documents from our web site or from Dri-calc is the quickest way to review our literature, we'd also be happy to mail to you any literature you need.

17 Installation Connecting humidifier to dispersion assembly with vapor hose maintain a minimum pitch of 2"/ft (15%) back to the humidifier. hose may use unacceptable release agents or material mixes that can affect humidifier system performance adversely. Using hose from alternative manufacturers increases the possibility of tank foaming and accelerated aging. Foaming causes condensate discharge at the dispersion assembly. aging, causing the vapor hose to become hard and susceptible to failure due to cracks. humidifier. DO NOT use hose with an inside diameter (ID) smaller than the humidifier steam outlet. use the recommend installation as shown in Figure Important: Failure to follow the recommendations in this section can result in excessive back pressures on the humidifier. This will result in unacceptable humidification system performance such as leaking gaskets, blown water seals, erratic water level control, and spitting condensate from the dispersion tube(s). Important: Reducing the inside diameter of the interconnecting piping will result in the internal humidifier system pressure exceeding the parameters for acceptable performance. Connecting humidifier to dispersion assembly with tubing or pipe requirements for specific applications. humidifier. DO NOT use interconnecting tubing or pipe with an inside diameter (ID) smaller than the humidifier steam outlet. adapters convert a tubing outlet on the humidifier to threaded pipe, allowing a pipe connection. apart. heavy wall pipe. More on the next page

18 Installation Connecting humidifier to dispersion assembly with tubing or pipe (continued) condensation. lubricants used to thread the pipe. This will minimize the possibility of tank foaming. Denatured alcohol or mineral spirits work best for removing lubricant. use the recommend installation as shown in Figure Table 18-1: Maximum steam carrying capacity and length of interconnecting vapor hose, tubing, and pipe* Vapor hose Copper or stainless steel tubing and Schedule 40 steel pipe Hose I.D. Maximum capacity Maximum length** Tube or pipe size*** Maximum capacity Maximum developed length inches DN lbs/hr kg/h ft m inches DN lbs/hr kg/h ft m 1½ ½ * Based on total maximum pressure drop in hose, tubing or piping of 5" wc (1250 Pa) ** Maximum recommended length for vapor hose is 10' (3 m). Longer distances can cause kinking or low spots. *** To minimize loss of capacity and efficiency, insulate tubing and piping. Developed length equals measured length plus 50% of measured length, to account for pipe fittings.

19 Installation Drip tee installation Install a drip tee as shown below when the humidifier is mounted higher than the dispersion assembly, when interconnecting hose or piping needs to go over an obstruction, or when interconnecting piping runs are long. Important: Vapor hose must be supported to prevent sagging or low spots. WARNING! Dispersion tube, vapor hose, tubing, or hard pipe can contain steam, and surfaces can be hot. Discharged steam is not visible. Contact with hot surfaces or air into which steam has been discharged can cause severe personal injury. Figure 19-1: Drip tee installation 90 long sweep or two 45 elbows Pitch Obstruction Insulate tubing and hard pipe to reduce steam loss CRUV humidifier To dispersion assembly 6" (150 mm) recommended 8" (200 mm) minimum Tubing or pipe drip tee, by installer. DRI-STEEM part numbers for 304 stainless steel inline tees: ¾" (DN20) 1" (25 mm) air gap Open funnel or floor drain. See first note below. DC-7548 Notes: to governing codes for drain pipe size and maximum discharge water temperature.

20 Installation Figure 20-1: Single tube without condensate drain Duct Vapor hose, tubing or pipe. Insulate tubing and hard pipe to reduce steam loss. Do not insulate vapor hose. See Table 18-1 for maximum piping lengths. Single dispersion tube without condensate drain Pitch* Mounting nut 3/8" - 16 (M10) CRUV humidifier Notes: * Pitch vapor hose, tubing or pipe toward humidifier: 2"/ft (15%) when using vapor hose 1/8"/ft (1%) when using tubing or pipe provided by installer OM-7554 Secure and seal escutcheon plates 90 long sweep or two 45 elbows See the first bullet in the notes below. Tube pitch: 2"/ft (15%) Dispersion tube escutcheon plate A Dimension A: A OM-7554 Table 20-1: Hose kit sizing by model Humidifier models CRUV 2-8 CRUV CRUV CRUV WARNING! Hose kit (vapor hose, dispersion tube and hardware) 1½" (DN40) hose kit without drain 1½" (DN40) hose kit with drain 2" (DN50) hose kit without drain 2" (DN50) hose kit without drain Maximum capacity of dispersion tube lbs/hr kg/h These models require multiple tube assemblies and cannot use a hose kit. Dispersion tube, vapor hose, tubing, or hard pipe can contain steam, and surfaces can be hot. Discharged steam is not visible. Contact with hot surfaces or air into which steam has been discharged can cause severe personal injury. Notes: outlet to hard pipe. Use a hose clamp to connect the steam outlet to vapor hose. Use a hose cuff and clamps to connect the steam outlet to tubing. less steam loss at start-up. 1½" (DN40) or 2" (DN50). 1½" (DN40): 28.4 lbs/hr (13 kg/h) 2" (DN50): 56.8 lbs/hr (25.8 kg/h) see Figure in excessive back pressures on the humidifier. This can lead to dispersion tube(s) spitting, steam blowing through water seals, or leaking gaskets. includes vapor hose, a dispersion tube and hardware. Note that the capacities of models CRUV-30 and CRUV-34 require multiple tube assemblies and therefore cannot use a hose kit. For multiple tube assemblies, see the Rapid-sorb section, beginning on Page 22.

21 Installation Figure 21-1: Single tube with condensate drain Vapor hose, tubing or pipe. Insulate tubing and hard pipe to reduce steam loss. Do not insulate vapor hose. See Table 18-1 for maximum piping lengths. Secure and seal escutcheon plates Duct Single dispersion tube without condensate drain 90 long sweep or two 45 elbows See the first bullet in the notes below. CRUV humidifier Notes: 1. Pitch vapor hose, tubing or pipe toward humidifier: 2"/ft (15%) when using vapor hose ½"/ft (5%) when using 1½" tubing or pipe ¼"/ft (2%) when using 2" tubing or pipe 2. Dashed lines indicate provided by installer Pitch (see Note 1 below) Water seal 5" (125 mm) 1" (25 mm) air gap 6" (150 mm) recommended ¼" NPT (DN8) Mounting nut 3/8" - 16 (M10) Pitch tube toward drain 1/8"/ft (1%) ½" O.D. (DN15) condensate drain tube. Pitch ¼ /ft (2%) toward escutcheon plate. ¾" (DN20) (minimum) condensate drain tube by installer. Must be suitable for 212 F (100 C) water. Open drain required. Locate air gap only in spaces with adequate temperature and air movement to absorb flash steam; otherwise, condensation may form on nearby surfaces. Refer to governing codes for drain pipe size and maximum discharge water temperature. OM-7549 Notes: outlet to hard pipe. Use a hose clamp to connect the steam outlet to vapor hose. Use a hose cuff and clamps to connect the steam outlet to tubing. causing less steam loss at start-up. size 1½" (DN40) or 2" (DN50). See the steam carrying capacities in Table ½" (DN40): 56.8 lbs/hr (25.8 kg/h) 2" (DN50): 85.2 lbs/hr (38.6 kg/h) see Figure in excessive back pressures on the humidifier. This can lead to dispersion tube(s) spitting, steam blowing through water seals, or leaking gaskets. Figure 21-2: Escutcheon plates Dispersion tube A A Dimension A: 1½" tubes 2" tubes WARNING! Condensate drain 3.25" (82.5 mm) 3.25" (82.5 mm) OM Dispersion tube, vapor hose, tubing, or hard pipe can contain steam, and surfaces can be hot. Discharged steam is not visible. Contact with hot surfaces or air into which steam has been discharged can cause severe personal injury.

22 Installation Important: Failure to follow the recommendations in this section can result in excessive back pressures on the humidifier. This will result in unacceptable humidification system performance such as leaking gaskets, blown water seals, erratic water level control, and spitting condensate from the dispersion tube(s). Table 22-1: Rapid-sorb dispersion tube capacities Tube capacity Tube diameter lbs/hr kg/h inches DN ½ Table 22-2: Rapid-sorb header capacities Header capacity Header diameter lbs/hr kg/h inches DN General Rapid-sorb installation instructions this manual. of all Rapid-sorb components with packing list. Report any shortages to DRI-STEEM factory immediately. The components typically include the following: Multiple dispersion tubes Header ¾" 2" (19 mm 51 mm) L-bracket A single duct escutcheon plate the size of the header Slip couplings or hose cuffs and clamps. Accessories such as duct plates, slip couplings, or hose cuffs are in a plastic bag. The bolts and washers for mounting the dispersion tubes to the bracket will be in the end of the tubes or packaged in a bag with the other accessories. The tubes, header, and L-bracket are tagged with the customer requested identification number written on each component. provides necessary access in and around the ductwork or air handler. duct, or is installed across the face of a coil in an air handler. closer than 4.5" (114 mm) from the side of the ductwork or air handler wall. L-brackets that are 50" (1270 mm) or less in length have a hole 4" (102 mm) in from each end to mount the L-bracket to the duct or air handler wall. L-brackets that are greater than 50" (1270 mm) in length have an additional hole in the center of the L-bracket. Important: Before marking and drilling holes in the duct or air handler, refer to ALL pitch requirements for the Rapid-sorb assembly you received (see the table on the next page). The size, quantity, and location of penetrations are determined by the specific dimensions and configuration of the Rapid-sorb assembly you received. Note: The hardware for mounting the L-bracket to the duct or air handler wall and the hardware for the header support bracket is not provided. Rapid-sorb installations installed in a duct horizontal airflow with Rapid-sorb header either inside or outside the duct. See the Dri-calc Installation Guides library or contact your representative/distributor or DRI-STEEM for installation instructions for air handler or vertical airflow applications.

23 Installation Rapid-sorb pitch requirements airflow duct, consider the following pitch issues: For 1½" (DN40) dispersion tubes use a fastener of sufficient length to accommodate the 1/8"/ft (1%) pitch requirements toward the ¾" pipe thread (DN20) header drain fitting. For 2" (DN50) dispersion tubes, the bracket can be mounted flush to the ductwork. The 1/8"/ft (1%) pitch typically can be accomplished in the length of the hose cuffs used to connect the tubes to the header. pitch requirements. Table 23-1: Pitch of interconnecting piping, dispersion tubes, and headers for Rapid-sorb evaporative dispersion units Airflow Type of interconnecting piping Diameter of interconnecting piping Pitch of interconnecting piping Pitch of dispersion tubes Pitch of header Horizontal Vapor hose Tubing or pipe 1½" (DN40) 2" (DN50) 1½" (DN40) 2" (DN50) 2"/ft (15%) toward Rapid-sorb 1/8"/ft (1%) toward Rapid-sorb Vertically plumb 1/8"/ft (1%) toward condensate drain Vertical Vapor hose Tubing or pipe 1½" (DN40) 2" (DN50) 1½" (DN40) 2" (DN50) 2"/ft (15%) toward Rapid-sorb 1/8"/ft (1%) toward Rapid-sorb 2"/ft toward header 1/8"/ft (1%) toward condensate drain

24 Installation Figure 24-1: Rapid-sorb dispersion assembly Position L-bracket so that flange is upstream of dispersion tubes. Drawing shows L-bracket positioned for airflow back to front. Dispersion tube L-bracket Airflow Point tubelets perpendicular to airflow Duct 90 long sweep or two 45 elbows Vapor hose, tubing or pipe. Insulate tubing and hard pipe to reduce steam loss. Do not insulate vapor hose. See Table 18-1 for maximum piping lengths. Slip coupling or hose cuff Notes: 1 Pitch vapor hose, tubing, or pipe toward Rapid-sorb: 2"/ft (15%) when using vapor hose 1/8"/ft (1%) when using tubing or pipe 2 Use DRI-STEEM s hard pipe adapter kit to connect the steam outlet to hard pipe. Use a hose clamp to connect the steam outlet to vapor hose. Use a hose cuff and clamps to connect the steam outlet to tubing. Pitch (see Note 1) Condensate drain ¾" pipe Header pitch: 1/8"/ft (1%) thread (DN20) copper minimum ¾" pipe thread (DN20) copper CRUV humidifier 1" (25 mm) air gap Secure and seal escutcheon plates Support bracket that has 0.421" (11 mm) mounting holes at top, bottom and end 6" (150 mm) recommended 5" (125 mm) recommended Open drain required. Locate air gap only in spaces with adequate temperature and air movement to absorb flash steam; otherwise, condensation may form on nearby surfaces. Refer to governing codes for drain pipe size and maximum discharge water temperature. OM-7550 Figure 24-2: Dispersion tube escutcheon plates WARNING! A Dimension A: 1½" tubes A 2" tubes OM Dispersion tube, vapor hose, tubing, or hard pipe can contain steam, and surfaces can be hot. Discharged steam is not visible. Contact with hot surfaces or air into which steam has been discharged can cause severe personal injury. Assembly and installation instructions for a Rapid-sorb installed with header outside the duct (horizontal airflow) 1. Locate and cut the holes in the ductwork for the dispersion tubes. Use the L-bracket as a template to locate the holes on the duct floor. 2. Temporarily, loosely suspend or support the header below the final location the vertical balance point of the dispersion tube length dictates where the header should be suspended or supported temporarily. 3. Mount the dispersion tubes to the header with the provided connector, either a slip coupling or a hose cuff. tubes, take care not to shear the O-rings. the O-ring is resting on the face of the tubing. lubrication is necessary, DO NOT use a petroleum-based lubricant.

25 Installation 4. Position the flange of the L-bracket so it is upstream of the tubes when the assembly is raised and fastened into position. Fasten the L-bracket to the end of the dispersion tubes with the provided bolt, lock washer, and flat washer. 5. Before tightening the L-bracket bolts to the dispersion tubes follow these instructions: The dispersion tube will rotate in the slip coupling. Verify that the dispersion tube orifices are directed perpendicular to the airflow. The dispersion tube and slip coupling must be fully engaged on to the header stub for the O-rings to provide a seal. Before securing the hose cuff in place with the hose clamps on the dispersion tube and the header stub, verify that the dispersion tube orifices are directed perpendicular to the airflow. 6. Slide the assembly up until the L-bracket aligns with the mounting holes in the duct. The header pitch is duplicated in the L-bracket. The dispersion tube and slip coupling must be fully engaged on to the header stub for the O-rings to provide a seal. The high end of the L-bracket can be fastened tight to the duct or air handler. On the low end of the L-bracket, the fastener must be long enough to compensate for the pitch, and a nut should be provided and secured on both sides of the L-bracket and the duct or air handler for stability. Fasten the bracket to the top of the duct and use the hose cuffs to compensate for the pitch of the header. Before securing the hose cuff in place with the hose clamps on the dispersion tube and the header stub, verify that the header pitch, 1/8"/ft (1%) toward drain, is maintained. 7. Permanently secure both ends of the header and verify that the header pitch, 1/8"/ft (1%) toward drain, is maintained. 8. Verify that all fasteners are secure: 9. Secure and seal the dispersion tube escutcheon plate and condensate drain tube escutcheon plate around the respective tubes, if applicable. Note: See Page 28 for steam supply and condensate drain line connection instructions.

26 Installation Figure 26-1: Rapid-sorb installed in a horizontal airflow with header inside the duct Position L-bracket so that flange is upstream of dispersion tubes. This drawing shows the L-bracket positioned for airflow back to front 90 long sweep or two 45 elbows Vapor hose, tubing or pipe. Insulate tubing and hard pipe to reduce steam loss. Do not insulate vapor hose. See Table 18-1 for maximum piping lengths. Note: * Pitch vapor hose, tubing, or pipe toward Rapid-sorb: 2"/ft (15%) when using vapor hose 1/8"/ft (1%) when using tubing or pipe Dispersion tube Point tubelets (steam orifices) perpendicular to airflow Slip coupling or hose cuff Pitch* Secure and seal escutcheon plate CRUV humidifier Pitch header toward drain 1/8"/ft (1%) ¾" pipe thread (DN20) drain ¾" (DN20) copper 1" (25 mm) air gap Duct Airflow 5" (127 mm) Support bracket 6" (152 mm) Open drain required. Locate air gap only in spaces with adequate temperature and air movement to absorb flash steam, or condensing on nearby surfaces may occur. Refer to governing codes for drain pipe size and maximum discharge water temperature. OM-7551 Assembly and installation instructions for a Rapid-sorb installed with header inside the duct (horizontal airflow) 1. Locate and cut the holes in ductwork or air handler for steam header penetration, condensate drain piping, and header support bracket fastener. Allow 1/8"/ft (1%) header pitch toward the support bracket when you drill the hole for the header support bracket fastener. 2. Loosely fasten the header in place. 3. Rotate the header 90 so the header stubs point horizontally in the duct. When installing in an air handler, the rotation of the header is often less than 90. Typically, due to the condensate drain piping requirements, the header can be set on the floor of the air handler, assembled in the vertical position, and then raised and mounted in place.

27 Installation 4. Mount the dispersion tubes on the header with the slip couplings or hose cuffs. tubes, take care not to shear the O-rings. the O-ring is resting on the face of the tubing. lubrication is necessary, DO NOT use a petroleum-based lubricant. 5. Allow the dispersion tubes to rest against the bottom of the duct. 6. Position the flange of the L-bracket so it is upstream of the tubes when the assembly is rotated into position. Fasten the L-bracket to the end of the dispersion tubes with the provided bolt, lock washer, and flat washer. 7. Rotate the assembly up until the L-bracket aligns with the mounting holes in the duct or air handler. The header pitch is duplicated in the L-bracket. The dispersion tube and slip coupling must be fully engaged on to the header stub for the O-rings to provide a seal. The high end of the L-bracket can be fastened tight to the duct or air handler. On the low end of the L-bracket, the fastener must be long enough to compensate for the pitch, and a nut should be provided and secured on both sides of the L-bracket and the duct or air handler for stability. Fasten the bracket to the top of the duct or air handler and use the hose cuffs to compensate for the pitch of the header. Before securing the hose cuff in place, with the hose clamps on the dispersion tube and the header stub, verify that the dispersion tube orifices are directed perpendicular to the airflow. 8. Verify that all fasteners are secure: 9. Secure and seal the header escutcheon plate around the header. 10. See the next page for steam supply and condensate drain line connection instructions. WARNING! Dispersion tube, vapor hose, tubing, or hard pipe can contain steam, and surfaces can be hot. Discharged steam is not visible. Contact with hot surfaces or air into which steam has been discharged can cause severe personal injury.

28 Installation Steam supply connections to the Rapid-sorb header 1. Connect the steam supply interconnecting piping from the humidifier to the Rapid-sorb. The steam supply piping requires a minimum of 1/8"/ft (1%) pitch toward the header. 2. If multiple humidifiers are supplying one Rapid-sorb, a multiple steam supply connector is provided. Rapid-sorb header supply end with hose cuff and clamps. humidifier tanks to the steam supply connector. supplies while maintaining the necessary pitch. header are tight. Condensate drain connections to the Rapid-sorb header 1. Piping must be minimum ¾" I.D. (DN20) and rated for 212 F (100 C) minimum continuous operating temperature. 2. Condensate drain line must be piped as shown in the figures on the previous pages. Provide a 6" (152 mm) drop prior to a 5" (127 mm) water seal to: 3. After the water seal, run the drain line to an open drain with a 1" (25 mm) vertical air gap. Cut the drain line at a 45 angle on the end above the drain to permit a direct stream of water into the drain pipe while maintaining a 1" (25 mm) air gap. Locate air gap only in spaces with adequate temperature and air movement to absorb flash steam; otherwise, condensing on nearby surfaces may occur. 4. All drain lines must be installed and sized according to governing codes.

29 Operation Introduction After the system is installed and connected properly, you can begin start-up procedures. Start-up and checkout procedures 1. Verify that the humidifier, controls, piping, electrical connections, steam supply, and dispersion unit(s) are installed according to the following: Installation section of this manual, beginning on Page 8 Vapor-logic3 Installation and Operation Manual, if using the Vapor-logic3 control option: Installation section Installation checklist 2. Verify that the humidifier is mounted level and securely supported before filling with water (see the operating weights in Table 6-1). 3. Verify that the humidifier is level front to back and side to side after it is full of water. 4. Refer to the LW417 section of this start-up procedure or the Vapor-logic3 Installation and Operation Manual the Operation section and the Start-up checklist (it is critical that the installer follow this checklist). 5. During start-up, do not leave the humidifier unattended. 6. Monitor humidifier operation through multiple fill cycles. 7. At start-up, DRI-STEEM recommends initially running the humidifier with the factory default setting for skim time. (See Adjusting skim duration on Page 34.) The CRUV humidifier is available with either the standard LW417 Electronic Water Level Control Module or the optional Vapor-logic3 microprocessor control system. If your system is equipped with the Vapor-logic3 system, see the Vapor-logic3 Installation and Operation Manual for more information. Then continue reading this manual beginning with the Maintenance section on Page 34. WARNING! Only qualified electrical personnel should perform start-up procedure. Contact with energized circuits can cause property damage, severe personal injury or death as a result of electrical shock or fire. CAUTION! In the event the humidifier tank does not contain water and the heaters are energized, turn main power off. Operation of the heaters without water will cause damage to the humidifier. Before turning main power on, verify that all wiring has been completed per the wiring instructions in this manual and the unit wiring diagrams. Note: The Vapor-logic3 Installation and Operation Manual is a comprehensive operation manual. Refer to it for information regarding the following features: information The Vapor-logic3 manual was shipped with your humidifier. Additional copies can be viewed, printed, or ordered at More on the next page

30 Operation Figure 30-1: Water level control for standard water systems A - Fill valve closes B - Fill valve opens C - Low-water cutoff VLC-OM-030 Figure 30-2: Water level control for DI/RO water systems Supply water connection Float rod Float ball Systems using deionized (DI) water or water that has been treated through reverse osmosis (RO) control water levels using a float valve and low water cutoff switch. VLC-OM-026 LW417 electronic water level control (for standard water units only) The LW417 is a custom microprocessor-based water level controller developed to operate with DRI-STEEM humidifiers. The features of this controller are: control (for standard water units) assist troubleshooting When power is activated, the solenoid-operated water fill valve opens, filling the evaporating chamber. Filling continues until the water reaches level A (see Figure 30-1), at which time the fill valve closes. To ensure that a water seal is created in the field installed water seal, disconnect the probe plug and cable from the probe rod assembly (located on top of the tank), allowing the fill valve to re-energize and overfill the humidifier tank. This process takes a short time. Reconnect the probe plug and cable. Create a call for humidify to ensure the steam valve opens. IMPORTANT: Timer logic input wire (see Figure 32-1) must be connected per wiring diagram for proper automatic drain and flush and end-of-season drain operation. The Power light blinks off twice at one-second intervals when these functions are disabled. Verify wiring with diagram supplied with unit. Water refill During operation, when the water line drops below level B, the fill valve opens and remains open until the water line returns to level A (see Figure 30-1). Low water condition Should the water line drop below level C, the steam value is de-energized and remains OFF until the water line is restored to level C. More on the next page

31 Operation Automatic drain and flush The control module contains an integral electronic timer that tracks the humidifying time of the unit. When this accumulated time reaches what has been set in the timer, the drain/flush cycle is activated. Upon activation, the following sequence occurs: 1. The drain valve opens, draining the mineral laden water from the evaporating chamber. 2. The default drain time is 10 minutes. 3. Flushing occurs during the last 10% of drain period. The electronic timer is factory set for drainage after 40 hours of operation. Alternate settings of 20 hours and 80 hours are available. See the wiring diagram(s) attached to the unit for timer board location and instructions for changing the timer setting or refer to Table Test cycling the drain/flush system The level control board incorporates a set of slide switches marked 1 through 8. To test: 1. Place SW1 slide switches 1, 2, and 3 to the off position. 2. Set the humidistat high enough so the unit remains on call for at least 15 minutes. 3. After about 2 minutes of operation, activation takes place, causing the drain valve to open. The water level then drops to level C (see Figure 30-1) and allows the fill valve to open. Both valves will remain open for the remainder of the autodrain and flush period. 4. The drain valve then closes, and the water level rises to level A (see Figure 30-1), causing the fill valve to close. 5. Once the test cycle is complete, return the slide switches back to the desired operating mode. Failure to do so will result in a drain/flush cycle every 2 minutes. End-of-season drain The end-of-season drain option drains the tank after 72 hours of no system demand to minimize microbial growth inside the humidifier. When there is a demand for humidity, the tank fills and the unit runs when the operating level is reached. Table 31-1: Autodrain settings Switch Drain time Interval time Self test Off Off Off 10 min. 2 min. Disabled On Off Off - - Option Off On Off 10 min. 20 hours Option On On Off 30 min. 20 hours Factory settings Off Off On 10 min. 40 hours Option On Off On 30 min. 40 hours Option Off On On 10 min. 80 hours Option On On On 30 min. 80 hours Variable skim times The skim time feature removes surface solids and foam from the water. This keeps the fill valve open for a certain amount of time after the water reaches level A (see Figure 30-1). The skim time is factory set for 32 seconds but can be changed in the field for locations with water that requires more skimming. See Adjusting skim duration on Page 34. See wiring diagram(s) shipped with the unit for timer board location and instructions for changing the skim time setting. More on the next page